Calculations for Gate Cross section

Depth of Gate (h) = n X t

h = Depth of Gate (mm)

n = material constant
Material Constant (n)
t = wall section thickness (mm)
Polyethylene 0.6
Polystyrene 0.6
n A Polyacetal 0.6
Gate Width (w) =
30 Polycarbonate 0.6
Polypropylene 0.7
w = Gate Width (mm)
Cellulose acetate 0.7
n = material constant
Acrylic 0.7
A = Surface area of cavity (mm²)
Nylon 0.8
Reference Book : Plastic Engineer's Data Book
PVC 0.9

digi MOLD 1
 Runner Calculation

Runner Diameter (D) 

W L
3.7
D = Runner Diameter (mm)
w = weight of molding (grams)
L = Length of runner (mm)

Reference Book : Plastic Engineer's Data Book

digi MOLD 2
 Runner Calculation

d1(mm) = Molding wall thickness (t) (mm)+1

d2 (mm) = d1(mm) X N1/3

d1 = Diameter Of runner connected to gate (mm)

d2 = Diameter Of runner feeding the runner(1) (mm)

d1 = Diameter Of runner(1) (mm)

N = Number of Runner branches

Reference Book : Runner & Gating Design Handbook

Author : John P. Beaumont

digi MOLD 3
 Shear Rate Calculations
32 X Q
Shear Rate Through Round Channel / sec = γ =
π X d3

6XQ
Shear Rate Through Rectangular Channel / sec = γ =
wXh
γ = Shear Rate /sec

Q = Flow Rate (mm3/sec)

d = Diameter of a round channel (mm)

W = Width of rectangular channel (mm)

h = Depth of rectangular channel (mm)

Q = [ Volume of the molding (V)(mm3)] / [Time required to fill the cavity (t) (sec) ]

Reference Book : Runner & Gating Design Handbook

Author : John P. Beaumont
digi MOLD 4
 Mold Cooling Calculations
Minimum Cooling Period Required (θ)

t2   Tx Tm
 log   
2  4  Tc Tm
θ = minimum cooling time required (sec)

t = Max. thickness of molding (cm)

a = Thermal diffusivity of material (Sq. Cm./Sec.)

Tx = Heat distortion temp. of material (˚C)

Tm = Temp. of mould (˚C)

Tc = Cylinder temp. (˚C)

Reference Book : Plastic Engineer's Data Book

digi MOLD 5
 Mold Cooling Calculations
Solidifying Time (T)

 a t2
T
p tmat  tmold  8

T = Solidifying time (sec)

γ = Specific weight (g/cm3)

a = Heat content of material (cal/g)

=The heat of solidification

λp= Thermal conductivity of plastics (cal/cm. Sec ˚C)

t = Wall thickness of the molding (cm)

tmat = injection temp. of material (˚C)

t mould = Temp. of mould (˚C)

Reference Book : Plastic Engineer's Data Book digi MOLD 6

 Mold Cooling Calculations

Heat to be transferred from mold per hour (Q)

Q =( m X a) X 0.5

Q = Heat to be transferred per hour (cal/hr)

m = Mass of plastics material injected into the mold/ hour (g/hr)

a = Heat content (cal/g)

Reference Book : Plastic Engineer's Data Book

digi MOLD 7
 Mold Cooling Calculations
Heat to be transferred from mold per hour (Q)

(Alternate Solution)

Q = m [cp (Tmat - Tmould) + L]

m = Mass of plastics material injected into the mold/ hour (g/hr)

Cp = Specific heat of material (Cal/g 0C)

L = Latent heat of fusion of plastics material (cal/g)

Tmat = Injection temperature of material (0C)

(However a value less than this is used in practice.)

Tmold = Temperature of mold (0C)

Reference Book : Plastic Engineer's Data Book

digi MOLD 8
 Mold Cooling Calculations

Quantity of cooling water to be circulated per hour to dissipate the heat (m1)

Qw = K.m1 (Tout - Tin)

Qw = Rate of heat extracted (cal/hr)

K = Constant to allow for heat transfer efficiency

m1 = Weight of water passed (g/hr)

(Tout - Tin) =Change in water temperature = (3 to 5) 0C

Reference Book : Plastic Engineer's Data Book

Values for constant K K

Cooling channels bored in cavity plate or male core 0.64
Cooling channels bored in back plate 0.5
Cooling channels using copper pipes 0.1

digi MOLD 9
 Mold Cooling Calculations
Total Length of Cooling Channel (L)

Q1  Z
L
ys tmat  tmold   Ac
2

Q1 = (Q/3600) cal/sec i.e. heat transferred per second

Ac = Area of Cross – Section of cooling channel (cm2)

ys = Thermal conductivity of steel cal/cm.sec ˚C

Z = Distance of cooling line from the molding surface (cm)

Tmat = Injection temperature of material (0C)

(However a value less than this is used in practice.)

Tmold = Temperature of mold (0C)

Reference Book : Plastic Engineer's Data Book

digi MOLD 10
 Mold Cooling Calculations
Check for turbulent flow

VXd
Reynolds number =
γ

V = velocity of liquid (cm/sec)

d = diameter of the cooling channel (cm)

γ = kinematic viscosity of the liquid (cm2/sec)

[kinematic viscosity of water = 1centistoke= 10-2 cm2/sec]

Reference Book : Plastic Engineer's Data Book

digi MOLD 11
 Mold Cooling Calculations
Recommended Distances of Cooling channels

 Minimum Distance between two cooling channels (B)

= [2.5 TO 3.5 ] X d

d = Diameter of cooling channel (d)

 Distance of cooling channels from molding surface (A)

= [0.8 TO 1.5 ] X d

d = Diameter of cooling channel (d)

Reference Book : Plastic Engineer's Data Book

digi MOLD 12
 Mold Cooling Calculations
Distance of Cooling Line from The Molding Surface (Z)

s  A  (Tmat Tmold )  T
Z
Qs
Z = Distance of cooling line from the molding surface (cm)

Qs = Solidified heat released when material is stiffening (cal)

A = Molding surface area (cm2)

λS = Thermal conductivity of steel (cal/cm sec.˚C)

T = Solidifying time (sec)

Reference Book : Plastic Engineer's Data Book

digi MOLD 13
 Mold Cooling Calculations
Distance of Cooling Line from The Molding Surface (Z)
(Alternate Solution)

s  A  (Tmat Tmold )  T
Z
Qs
Qs = γ X A X t X a

Z = Distance of cooling line from the molding surface (cm)

Qs = Solidified heat released when material is stiffening (cal)

t = Wall thickness of the molding (cm)

a = Heat content of material (cal/g) , A = Molding surface area (cm2)

γ = Specific weight (g/cm3) , T = Solidifying time (sec)

λS = Thermal conductivity of steel (cal/cm sec.˚C)

Reference Book : Plastic Engineer's Data Book

digi MOLD 14
 Calculations for the minimum thickness of Cavity Wall (t)

c. p.d 4
t3
E. y.

Ratio of the length of Cavity wall Values of

t = Thickness of Cavity wall (Cm)
to the depth of Cavity wall (L/d) 'C'
y = Max. deflection of side walls (Cm.)

C = constant 1 0.044

p = Max. cavity pressure; say 630 kg/Cm2 1.5 0.084

2 0.111
d = Total depth of Cavity wall (Cm)
3 0.134
E = Modules of elasticity for steel (Kgf/cm2) 4 0.14

5 0.142

Reference Book : Plastic Engineer's Data Book

digi MOLD 15
 Mold Locking Force Calculations

Required mold locking force (FREQD)(KN) =

Projected area of molding including Runner & gate (A)(mm2)

X Max. Injection pressure (P) (N/mm2)

digi MOLD 16
 Demolding Force Calculation
S .t . E . A . 
Demolding Force Required = P 
 d d 
d  
 2 t 4 t 
P = Demolding Force (Kgf) (1Kgf = 10 N) , t = Thickness of molding (cm)

E = Elastic Modulus (kgf/cm²) (1 Mpa = 10 Kgf/cm2) , γ = Poisson’s Ratio

A = Total area of contact between molding (cm2)

= Length of perimeter of molding surrounding slide (L)(cm) X Depth of molding in slide (h) (cm)

d = Diameter of circle of circumference equal to length of perimeter of molding surrounding

male core (cm)

S = thermal contraction of plastic across diameter 'd‘ (cm)

= co-efficient of thermal expansion (/˚C) X temp difference between softening
point & ejection temp (˚C) X d (cm)

µ = Coefficient of friction between plastic & steel (µ)

Reference Book : Plastic Engineer's Data Book digi MOLD 17

 Calculations for the Force acting on Finger cam

Ө pp
Ө
ӨӨ

Force acting on Finger cam =

(Weight of slide + demolding force required)

X [ 1 + ( 4 X µ X ( µ X cos Ө + sin Ө) ) ]
(( 4 X µ2 X cos Ө)+( 2 X µ X sin Ө ) + (sin(90-Ө))

µ = Coefficient of friction of steel moving against steel

Ө = Angle of inclination of finger cam

Min. Required Diameter of Finger cam =

( Force acting on Finger cam X Open length of finger cam )⅓

(( π / 16) X ( Yield Strength of Finger cam material / F.O.S.) )⅓
digi MOLD 18
 Calculations for the Force acting on Finger cam
(Alternate Solution)

Force acting on Finger cam (F) = (Weight of slide + demolding force reqd.)
X ( 1 + tan2 β )0.5 X cos Ө

F = Force acting on finger cam

angle β = ( Ө + ρ )º

Ө = Angle of inclination of finger cam

ρ =Angle made by resultant force acting on finger cam with the axis normal finger cam

tan ρ = R / N = µ X N / N = µ

µ = Coefficient of friction of steel moving against steel

R = Frictional force

N = Normal reaction due to frictional force R

Q = (Weight of slide + demolding force required) digi MOLD 19

 Calculation for Plate Deflection & Stress

N X M3
Deflection in Plate = f =
48 X E X I

f = Deflection of Plate (mm)

N= Unit Load acting on plate (N)

= [ Projected area of cavity (A)(mm2) X
Max. Injection Pressure (P)(N/mm2) ] / W

W = Width of support plate (mm)

E = Modulus of Elasticity (N/mm2)

I = Moment of Inertia (mm4)

= [1(mm) X (Thickness of plate in ( mm) )3 / 12 ]

M = Distance between the support pillar (mm)

digi MOLD 20
Reference Book : Plastic Engineer's Data Book
 Calculation For The Unscrewing Forces

P (bar) X 0.1
Holding Pressure(N/mm2) =
100
P = Max. Injection Pressure (bar)

Effective Core Surface Area (mm2) = d(mm) X 3.14 X h X 2

d = Thread Diameter (mm) & h = Thread Height (mm)

Unscrewing Torque (N-mm) = Holding Pressure(N/mm2) X Thread Radius (mm)

X Effective Core Surface Area (mm2)

Unscrewing Force (KN) = [ Unscrewing Torque (N-mm) X No. of Cores ] /

[Pitch circle Radius of Gear (mm) X1000 ]

Hydraulic Force (KN) = Unscrewing Force (KN) X 1.5 ( 50% safety)

digi MOLD 21
Calculation For The Unscrewing Forces
( Example )

6.0 KN

30 KN

4.5 KN

3.0 KN

3.0 KN

1.5KN

3.0 KN

1.5KN

digi MOLD 22
 OU
K Y
A N
T H

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